Thermosetting wide range polymer blends

Abstract

The present invention economically recovers wide range polymer blends and waste thermoset material. A first method of thermosetting a wide range polymer blend forms a homogenous and adaptable first method material. This material has a melt index of zero and a relatively predictable density. Very high levels of fibrous non-polymers may be added to the first method material.

I claim: 
     
       1. A compatiblizing thermosetting process to form a first method material comprising: (a) a processing mixture comprising 25 to nearly 100 weight percent of a polymer blend and a small amount of a crosslinking agent sufficient to cause the polymer blend and the processing mixture to become thermoset with a melt index of zero just before the processing mixture is released from a mixing chamber of a mixing means of the process;   (b) the polymer blend comprising at least 50 weight percent of a thermoplastic polyolefins mixture, such thermoplastic polyolefins mixture consisting of substantial amounts of different thermoplastic polyolefins, such different polyolefins having been previously and separately melted for processing or substantial amounts of different thermoplastic polyethylene resins of high and low densities or high and low molecular weights and previously and separately melted for processing;   (c) subjecting the processing mixture to thermokinetic, intensive mixing within a thermokinetic mixing chamber of a thermokinetic mixing means wherein within such chamber the processing mixture rises to at least to the temperature at which the crosslinking agent causes crosslinking in the polymer blend;   (d) maintaining the thermokinetic, intensive mixing of the processing mixture in the thermokinetic mixing chamber until the processing mixture is thermoset and has a melt index of zero, at which time it becomes the first method material incapable of being extruded; and   (e) releasing the first method material from the thermokinetic mixing chamber.   
     
     
       2. The process of claim 1 wherein the processing mixture comprising 10 to almost 75 weight percent non-synthetic fibrous materials. 
     
     
       3. The process of claim 1 wherein the polymer blend further comprises about 1 to 15 weight percent of styrenic resins. 
     
     
       4. The process of claim 1 wherein the polymer blend further comprises about 1 to 10 weight percent of chlorinated polyolefins. 
     
     
       5. The process of claim 1 wherein the polymer blend further comprises about 1 to 25 weight percent of amine resins. 
     
     
       6. The process of claim 1 wherein the polymer blend further comprises about 1 to 25 weight percent of aromatic acid resins. 
     
     
       7. The process of claim 1 wherein the polymer blend further comprises about 1 to 50 weight percent of thermoset polymers. 
     
     
       8. A compatiblizing thermosetting process to form a first method material comprising: (a) a processing mixture comprising 25 to nearly 100 weight percent of a polymer blend and a small amount of a crosslinking agent sufficient to cause the polymer blend and the processing mixture to become thermoset with a melt index of zero just before the processing mixture is released from a mixing chamber of mixing means of the process;   (b) the polymer blend comprising at least 50 weight percent of a thermoplastic polyolefins mixture, such thermoplastic polyolefins mixture consisting of substantial amounts of different thermoplastic polyolefins, such different polyolefins having been previously and separately melted for processing or substantial amounts of different thermoplastic polyethlene resins of high and low densities or high and low molecular weights and previously and separately melted for processing;   (c) subjecting the processing mixture to shearing, heated mixing within a tubular barrel mixing chamber of and extruder mixing means wherein within such chamber the processing mixture rises to at least to the temperature at which the crosslinking agent causes crosslinking in the polymer blend;   (d) maintaining the shearing, heated mixing of the processing mixture in the tubular barrel mixing chamber until the processing mixture is thermoset and has a melt index of zero, at which time it becomes the first method material material incapable of being extruded; and   (e) forcing the first method material from the tubular barrel mixing chamber.   
     
     
       9. The process of claim 8 wherein the processing mixture comprises 10 to almost 75 weight percent non-synthetic fibrous materials. 
     
     
       10. The process of claim 8 wherein the polymer blend further comprises about 1 to 15 weight percent of styrenic resins. 
     
     
       11. The process of claim 8 wherein the polymer blend further comprises about 1 to 10 weight percent of chlorinated polyolefins. 
     
     
       12. The process of claim 8 wherein the polymer blend further comprises about 1 to 25 weight percent of amine resins. 
     
     
       13. The process of claim 8 wherein the polymer blend further comprises about 1 to 25 weight percent of aromatic acid resins. 
     
     
       14. The process of claim 8 wherein the polymer blend further comprises about 1 to 50 weight percent of thermoset polymers.